Haptic actuator including outwardly extending terminals from first and second housing shells and related methods

ABSTRACT

A haptic actuator may include a housing that includes first and second shells coupled together. The first shell may include a first body and first terminals extending outwardly therefrom. The second shell may include a second body and second terminals extending outwardly therefrom with each of the second terminals being secured with a respective one of the first terminals defining pairs of first and second secured-together terminals. The haptic actuator may also include at least one coil carried by the housing and a field member movable within the housing responsive to the at least one coil. A respective flexure may be between adjacent end portions of the housing and the field member.

RELATED APPLICATIONS

The present application claims the priority benefit of provisional application Ser. No. 62/904,569 filed on Sep. 23, 2019, the entire contents of which are herein incorporated by reference.

TECHNICAL FIELD

The present disclosure relates to the field of electronics, and, more particularly, to the field of haptics.

BACKGROUND

Haptic technology is becoming a more popular way of conveying information to a user. Haptic technology, which may simply be referred to as haptics, is a tactile feedback based technology that stimulates a user's sense of touch by imparting relative amounts of force to the user.

A haptic device or haptic actuator is an example of a device that provides the tactile feedback to the user. In particular, the haptic device or actuator may apply relative amounts of force to a user through actuation of a mass that is part of the haptic device. Through various forms of tactile feedback, for example, generated relatively long and short bursts of force or vibrations, information may be conveyed to the user.

SUMMARY

A haptic actuator may include a housing that includes first and second shells coupled together. The first shell may include a first body and a first plurality of terminals extending outwardly therefrom. The second shell may include a second body and a second plurality of terminals extending outwardly therefrom with each of the second plurality of terminals being secured with a respective one of the first plurality of terminals defining pairs of first and second secured-together terminals. The haptic actuator may also include at least one coil carried by the housing and a field member movable within the housing responsive to the at least one coil. A respective flexure may be between adjacent end portions of the housing and the field member.

The haptic actuator may also include a respective welded joint securing each pair of first and second secured-together terminals. The first and second respective terminals of each pair of secured-together terminals may be coextensive, for example.

Each of the plurality of first and second terminals may have a fastener receiving passageway therein. The field member may include a frame having opposing first and second ends and first and second overmolded endcaps coupled to the first and second ends of the frame, respectively, for example.

The haptic actuator may also include a respective plastic body between each respective flexure and adjacent end portions of the housing, for example. The field member may include a frame and at least one permanent magnet carried by the frame.

The housing may include a magnetic material. The flexures may have a wishbone shape, for example. The at least one coil may have a loop shape, for example.

A method aspect is directed to a method of making a haptic actuator that may include coupling first and second shells of a housing together. The first shell may include a first body and a first plurality of terminals extending outwardly therefrom. The second shell may include a second body and a second plurality of terminals extending outwardly therefrom. The first and second shells may be coupled so that each of the second plurality of terminals being secured with a respective one of the first plurality of terminals define pairs of first and second secured-together terminals. The method may also include positioning at least one coil carried by the housing and positioning a field member to be movable within the housing responsive to the at least one coil. The method may further include positioning a respective flexure between adjacent end portions of the housing and the field member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an electronic device in accordance with an embodiment.

FIG. 2 is a schematic block diagram of the electronic device of FIG. 1.

FIG. 3 is a perspective view of an exemplary haptic actuator in accordance with an embodiment.

FIG. 4 is a perspective view of the haptic actuator of FIG. 3 with the first shell of the actuator housing removed.

FIG. 5 is an exploded perspective view of a portion of a haptic actuator in accordance with an embodiment.

FIG. 6 illustrates assembly of an exemplary haptic actuator in accordance with an embodiment.

FIG. 7 is a perspective view of a flexure of a haptic actuator in accordance with an embodiment.

FIG. 8 is a cut-away view of a portion of a haptic actuator in accordance with an embodiment.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

Referring initially to FIGS. 1-2, an electronic device 20 illustratively includes a device housing 21 and a controller 22 carried by the device housing. The electronic device 20 is illustratively a mobile wireless communications device, for example, a cellular telephone or smartphone. The electronic device 20 may be another type of electronic device, for example, a wearable device (e.g., a watch), a tablet computer, a laptop computer, a gaming device, etc.

Wireless communications circuitry 25 (e.g. cellular, WLAN Bluetooth, etc.) is also carried within the device housing 21 and coupled to the controller 22. The wireless communications circuitry 25 cooperates with the controller 22 to perform at least one wireless communications function, for example, for voice and/or data. In some embodiments, the electronic device 20 may not include wireless communications circuitry 25.

A display 23 is also carried by the device housing 21 and is coupled to the controller 22. The display 23 may be, for example, a light emitting diode (LED) display, a liquid crystal display (LCD), or may be another type of display, as will be appreciated by those skilled in the art. The display 23 may be a touch display and may cooperate with the controller 22 to perform a device function in response to operation thereof. For example, a device function may include a powering on or off of the electronic device 20, initiating communication via the wireless communications circuitry 25, and/or performing a menu function.

The electronic device 20 illustratively includes a haptic actuator 40. The haptic actuator 40 is coupled to the controller 22 and provides haptic feedback or a haptic effect to the user in the form of relatively long and short vibrations. The vibrations may be indicative of a message received, and the duration and type of the vibration may be indicative of the type of message received. Of course, the vibrations may be indicative of or convey other types of information.

While a controller 22 is described, it should be understood that the controller 22 may include one or more of a processor and other circuitry to perform the functions described herein. For example, the controller 22 may include a class-D amplifier to drive the haptic actuator 40 and/or sensors for sensing voltage and current.

Referring now additionally to FIGS. 3-8, the haptic actuator 40 includes an actuator housing 41 that may be metal, for example, and more particularly, may include a magnetic material. The actuator housing 41 may be another type of material or include more than one type of material.

The actuator housing 41 includes first and second shells 42 a, 42 b that are coupled together. The first shell 42 a includes a first body 71 a and first terminals 72 a that extend outwardly from the first body. The first shell 42 a also includes first tabs 77 a extending from the first body 71 a. A cosmetic label 81 may be carried by the first shell.

The second shell 42 b includes a second body 71 b and second terminals 72 b that extend outwardly from the second body. The second shell 42 b also includes second tabs 77 b extending from the second body 71 b.

The first tabs 77 a each define a respective gap with each of the second tabs 77 b. The first and second tabs 77 a, 77 b each have a curved shape to define a rounded edge.

Each of the second terminals 72 b is secured with a respective one of the first terminals 72 a defining pairs of first and second secured-together terminals 72. Each of the first and second terminals 72 a, 72 b has a fastener receiving passageway 75 therein. A respective fastener passes through each fastener receiving passageway 75 to fasten the haptic actuator 40 within the device housing 21, and more particularly, adjacent the display 23.

The first and second terminals 72 a, 72 b of each pair of secured-together terminals 72 are coextensive. A respective welded joint 74 secures each pair of first and second-secured together terminals 72.

The haptic actuator 40 also includes first and second coils 44, 45 carried by the actuator housing 41, for example, the top and the bottom, respectively. The first and second coils 44, 45 may each have a loop shape or “racetrack” shape and are aligned in a stacked relation and spaced apart. There may be any number of first and second coils 44, 45 as will be appreciated by those skilled in the art. The haptic actuator 40 also includes a field member 50 that is movable within the actuator housing 41 responsive to the first and second coils 44, 45.

The field member 50 includes a frame 57 that defines a mass. The frame 57 has opposing first and second ends 53 a, 53 b. The frame 57 may be metal, for example, tungsten or tungsten powder. The frame 57 may be a different material (e.g., relatively heavy material). The frame 57 illustratively includes cleating 54 at the opposing ends 53 a, 53 b. Cleating 54 may be included in other areas, for example, relatively high-stress areas.

The field member 50 also includes permanent magnets 51 carried by the frame 57 and between the first and second coils 44, 45. More particularly, the permanent magnets 51 are configured in side-by-side relation and carried within a respective magnet receiving opening 64. An overmolded magnet receiving holder 58 is coupled to the frame 57 and lines corners of the magnet receiving opening 64 to receive the permanent magnets 51 therein. The permanent magnets 51 may be press-fitted to a magnetic center to reduce or minimize magnetic flux bias, as will be appreciated by those skilled in the art.

The permanent magnets 51 may be neodymium, for example, and may be positioned in opposing directions with respect to their respective poles. There may be any number of permanent magnets 51 having any shape between the first and second coils 44, 45. In some embodiments, the coils 44, 45 may be carried by the field member 50 and the permanent magnets 51 carried by the housing (i.e., movable coils).

The field member 50 illustratively includes a first overmolded endcap 55 a coupled to the first end 53 a of the frame 57. More particularly, the first end 53 a of the frame 57 (e.g., the cleating 54) is embedded into the first overmolded endcap 55 a. The first overmolded endcap 55 a may be plastic, such as a thermosetting or thermoplastic material. The first overmolded endcap 55 a may be another material or may include additional materials. For example, tungsten powder (to increase the weight) or glass (to increase the strength) may be included within the first overmolded endcap 55 a.

A second overmolded endcap 55 b is coupled to the second end 53 b of the frame 57. More particularly, similarly to the first end 53 a, the second end 53 b of the frame 57 (e.g., the cleating 54) is embedded into the second overmolded endcap 55 b. The second overmolded endcap 55 b may be plastic. The second overmolded endcap 55 b may be another material or may include additional materials. For example, tungsten powder or glass may be included within the second overmolded endcap 55 b.

The haptic actuator 40 also includes a first flexure 60 a having an inner end coupled to, for example, embedded into, the first overmolded endcap 55 a. The first flexure 60 a also has an outer end coupled to adjacent portions of the actuator housing 41. More particularly, a first plastic body 56 a is coupled to the outer end of the first flexure 60 a and carried by the actuator housing 41. The outer end of the first flexure 60 a is embedded within the first plastic body 56 a.

More particularly, the first plastic body 56 a has recesses 78 a, 78 b therein to receive the corresponding first and second tabs 77 a, 77 b therein. The first plastic body 56 a fills the respective gap defined by the first and second tabs 77 a, 77 b. The first plastic body 56 a also has a curved shape to define, with respective first and second tabs 77 a, 77 b, the rounded edges.

The first flexure 60 a illustratively includes two diverging arms 61 joined together by a bend 62 defining a wishbone shape. The two diverging arms 61 have cleating 63 or surface features at distal ends opposite the bend 62. The cleating 63 is illustratively encapsulated by the first plastic body 56 a and the first overmolded endcap 55 a. The first flexure 60 a may be metal, for example. Of course, the first flexure 60 a may be another material or may include other and/or additional materials. While a single first flexure 60 a is illustrated, there may be more than one first flexure.

The haptic actuator 40 also includes a second flexure 60 b having an inner end coupled to, for example, embedded into, the second overmolded endcap 55 b. The second flexure 60 b also has an outer end coupled to adjacent portions of the actuator housing 41. More particularly, a second plastic body 56 b is coupled to the outer end of the second flexure 60 b and carried by the actuator housing 41. The outer end of the second flexure 60 b is embedded within the second plastic body 56 b.

More particularly, the second plastic body 56 b has recesses 78 a, 78 b therein to receive the corresponding first and second tabs 77 a, 77 b therein. The second plastic body 56 b fills the respective gap defined by the first and second tabs 77 a, 77 b. The second plastic body 56 b also has a curved shape to define, with respective first and second tabs 77 a, 77 b, the rounded edges.

The second flexure 60 b, similarly to the first flexure 60 a, illustratively includes two diverging arms 61 joined together by a bend 62 to define a wishbone shape. The two diverging arms 61 have cleating 63 at distal ends opposite the bend 62. The cleating 63 is illustratively encapsulated by the second plastic body 56 b and the second overmolded endcap 55 b. The second flexure 60 b may be metal, for example. Of course, the second flexure 60 b may be another material or may include other and/or additional materials. While a single second flexure 60 b is illustrated, there may be more than one second flexure.

As will be appreciated by those skilled in the art, the haptic actuator 40 described herein may include a reduced part count, and may include reduced welding, gluing, and inspection operations relative to prior art haptic actuators, for example, by reducing and combining processes. Additionally, complexity of docking or mounting the field member 50 and flexures 60 a, 60 b within the actuator housing 41, may be reduced as the molded components may be considered self-aligning. With respect to volume efficiency, as described above, for example, mold features and tungsten powder compounding may be utilized to increase material volume and shapes. The use of compound materials and mold strategic shapes/locations of the haptic actuator 40 may also optimize resonance and damping characteristics.

With respect to drop shock, flexure breakage may be reduced since overmolding is typically done at lower temperatures relative to welding, for example. Moreover, the materials and shapes may be chosen to define moldable shock tolerant features, for example, crash stops.

In some embodiments, the frame 57 may be entirely plastic. For example, the frame 57, as being entirely plastic, may be integrally molded with the first and second overmolded endcaps 55 a, 55 b. Other and/or additional components may also be plastic and integrally molded with the fully plastic frame 57.

A method aspect is directed to a method of making a haptic actuator 40. The method includes coupling first and second shells 42 a, 42 b of a housing 41 together. The first shell 42 a includes a first body 71 a and a first plurality of terminals 72 a extending outwardly therefrom. The second shell 42 b includes a second body 71 b and a second plurality of terminals 72 b extending outwardly therefrom. The first and second shells 42 a, 42 b are coupled so that each of the second plurality of terminals 72 b being secured with a respective one of the first plurality of terminals 72 a define pairs of first and second secured-together terminals 72. The method also includes positioning at least one coil 44 carried by the housing 41 and positioning a field member 50 to be movable within the housing responsive to the at least one coil. The method further includes positioning a respective flexure 60 a, 60 b between adjacent end portions of the housing 41 and the field member 50.

Another method aspect is directed to a method of making a haptic actuator 40. The method includes coupling first and second shells 42 a, 42 b of a housing 41 together. The first shell 42 a includes a first body 71 a and a first plurality of tabs 77 a extending therefrom. The second shell 42 b includes a second body 71 b and a second plurality of tabs 77 b extending therefrom. The method includes positioning at least one coil 44 carried by the housing 41 and positioning a field member 50 to be movable within the housing responsive to the at least one coil. The method also includes positioning a respective flexure 60 a, 60 b between adjacent end portions of the housing 41 and the field member 50. Each flexure 60 a, 60 b includes a plastic body 56 a, 56 b having a plurality of recesses 78 a, 78 b therein to receive corresponding ones the first and second pluralities of tabs 77 a, 77 b therein.

Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims. 

That which is claimed is:
 1. A haptic actuator comprising: a housing comprising first and second shells coupled together, the first shell comprising a first body and a first plurality of terminals extending outwardly therefrom, the second shell comprising a second body and a second plurality of terminals extending outwardly therefrom with each of the second plurality of terminals being secured with a respective one of the first plurality of terminals defining pairs of first and second secured-together terminals; at least one coil carried by the housing; a field member movable within the housing responsive to the at least one coil; and a respective flexure between adjacent end portions of the housing and the field member.
 2. The haptic actuator of claim 1 comprising a respective welded joint securing each pair of first and second secured-together terminals.
 3. The haptic actuator of claim 1 wherein the first and second respective terminals of each pair of secured-together terminals are coextensive.
 4. The haptic actuator of claim 1 wherein each of the plurality of first and second terminals has a fastener receiving passageway therein.
 5. The haptic actuator of claim 1 wherein the field member comprises a frame having opposing first and second ends and first and second overmolded endcaps coupled to the first and second ends of the frame, respectively.
 6. The haptic actuator of claim 1 further comprising a respective plastic body between each respective flexure and adjacent end portions of the housing.
 7. The haptic actuator of claim 1 wherein the field member comprises a frame and at least one permanent magnet carried by the frame.
 8. The haptic actuator of claim 1 wherein the housing comprises a magnetic material.
 9. The haptic actuator of claim 1 wherein the flexures have a wishbone shape.
 10. The haptic actuator of claim 1 wherein the at least one coil has a loop shape.
 11. An electronic device comprising: a device housing; wireless communications circuitry carried by the housing; a haptic actuator carried by the device housing and comprising an actuator housing comprising first and second shells coupled together, the first shell comprising a first body and a first plurality of terminals extending outwardly therefrom, the second shell comprising a second body and a second plurality of terminals extending outwardly therefrom with each of the second plurality of terminals being secured with a respective one of the first plurality of terminals defining pairs of first and second secured-together terminals, at least one coil carried by the actuator housing, a field member movable within the actuator housing responsive to the at least one coil, and a respective flexure between adjacent end portions of the actuator housing and the field member; and a controller coupled to the wireless communications circuitry and the haptic actuator and configured to perform at least one wireless communications function and selectively operate the haptic actuator, respectively.
 12. The electronic device of claim 11 wherein the haptic actuator comprises a respective welded joint securing each pair of first and second secured-together terminals.
 13. The electronic device of claim 11 wherein the first and second respective terminals of each pair of secured-together terminals are coextensive.
 14. The electronic device of claim 11 wherein each of the plurality of first and second terminals has a fastener receiving passageway therein.
 15. The electronic device of claim 11 wherein the field member comprises a frame having opposing first and second ends and first and second overmolded endcaps coupled to the first and second ends of the frame, respectively.
 16. A method of making a haptic actuator comprising: coupling first and second shells of a housing together, the first shell comprising a first body and a first plurality of terminals extending outwardly therefrom, the second shell comprising a second body and a second plurality of terminals extending outwardly therefrom, the first and second shells being coupled so that each of the second plurality of terminals being secured with a respective one of the first plurality of terminals define pairs of first and second secured-together terminals; positioning at least one coil carried by the housing; positioning a field member to be movable within the housing responsive to the at least one coil; and positioning a respective flexure between adjacent end portions of the housing and the field member.
 17. The method of claim 16 comprising forming a respective welded joint to secure each pair of first and second secured-together terminals.
 18. The method of claim 16 wherein the first and second respective terminals of each pair of secured-together terminals are coextensive.
 19. The method of claim 16 wherein each of the plurality of first and second terminals has a fastener receiving passageway therein.
 20. The method of claim 16 wherein the field member comprises a frame having opposing first and second ends and first and second overmolded endcaps coupled to the first and second ends of the frame, respectively.
 21. The method of claim 16 further comprising positioning a respective plastic body between each respective flexure and adjacent end portions of the housing. 